Lochinvar EcoKnight Series Installation, Commissioning And Maintenance Instructions Download

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The EcoKnight™ range

High Efficiency Gas Fired Condensing Water Heaters

Installation, Commissioning and Maintenance
Instructions

Models:

EKW45CE

EKW60CE

EKW85CE

EKW115CE

EKW145CE

EKW175CE

EKW205CE

EKW235CE

INS0011 Issue No 9 | October 2013

Summary of Contents for EcoKnight Series

Page 1: ...ange High Efficiency Gas Fired Condensing Water Heaters Installation Commissioning and Maintenance Instructions Models EKW45CE EKW60CE EKW85CE EKW115CE EKW145CE EKW175CE EKW205CE EKW235CE INS0011 Issue No 9 October 2013 ...

Page 2: ...SUPPLY 24 9 1 COMBUSTION VENTILATION 24 9 2 COOLING VENTILATION 24 10 0 WATER CONNECTIONS 25 10 1 GENERAL 25 10 2 OPEN VENTED SYSTEM ARRANGEMENT 25 10 3 UNVENTED SYSTEM ARRANGEMENT 25 10 3 1 EXPANSION VESSEL SIZING 26 10 4 DE STRATIFICATION 26 10 5 CIRCULATING PUMPS 26 10 6 FLOW TEMPERATURE SENSOR 27 10 6 1 DRY POCKET SENSOR 27 10 6 2 STRAP ON SENSOR 27 10 6 3 SENSOR WIRING 27 11 0 ELECTRICAL SUPP...

Page 3: ...NSPECTION AND REPLACEMENT STORAGE VESSELS 48 15 9 REFILLING THE SYSTEM 48 15 10 OTHER CHECKS 49 15 10 1 RELIEF VALVE 49 15 10 2 FLUE SYSTEM 49 15 10 3 CONDENSATE NEUTRALISATION KIT 49 16 0 SMART SYSTEM CONTROL SETTINGS 49 16 1 ENTERING THE INSTALLER CODE 49 16 2 MENU SET D FUNCTIONS 50 16 2 1 RESET LAST 10 ERRORS 50 16 2 2 SERVICE MODE DELAY 50 16 3 MENU SET E WHR SETTINGS 50 16 3 1 TANK SETPOINT ...

Page 4: ...4 LPG FUEL This equipment MUST NOT use gas other than that for which it has been designed and adjusted This equipment must be installed by a competent person registered with a H S E approved body All installations must conform to the relevant Gas Safety and Building Regulations Health Safety requirements must also be taken into account when installing any equipment Failure to comply with the above...

Page 5: ... the heat exchanger either 1 1 4 or 2 depending on the model 14 Gas connection pipe Threaded pipe connection 1 2 3 4 or 1 depending on the model This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the water heater 15 SMART Control Module The SMART Control responds to internal and external signals and controls the fan gas valve and pumps to meet the demand ...

Page 6: ...6 FRONT VIEW MODELS EKW45CE EKW60CE LEFT SIDE INSIDE UNIT MODELS EKW45CE EKW60CE REAR VIEW MODELS EKW45CE EKW60CE RIGHT SIDE INSIDE UNIT MODELS EKW45CE EKW60CE ...

Page 7: ...7 REAR VIEW MODEL EKW85CE EKW115CE REAR VIEW MODEL EKW145CE LEFT SIDE INSIDE UNIT MODEL EKW85CE EKW115CE LEFT SIDE INSIDE UNIT MODEL EKW145CE ...

Page 8: ...8 REAR VIEW MODEL EKW175CE EKW235CE LEFT SIDE INSIDE UNIT MODEL EKW175CE EKW235CE ...

Page 9: ...et connection size BSP 1 1 1 1 1 WATER DATA Water content litres 4 9 6 4 9 1 12 9 15 9 15 9 18 9 21 6 Water connections F R BSP 1 2 Max water pressure PMS bar 11 0 Min water pressure bar 0 5 Test pressure bar 16 5 Maximum water temperature C 80 FLUE DATA TYPE B23 Nominal flue diameter mm 80 100 150 Maximum flue gas temp C 120 Maximum equivalent length m 60 Equivalent length 90 bend mm 1000 1500 Eq...

Page 10: ...10 FIGURE 3 1 ENCLOSURE INSTALLATION CLEARANCES mm FIGURE 3 2 PLANT ROOM INSTALLATION CLEARANCES mm 400 400 ...

Page 11: ... ventilation for gas appliances of rated input not exceeding 70kW net 1st 2nd and 3rd family gases Part 1 Specification for installation and maintenance of flues BS 5440 2 2009 Installation and maintenance of flues and ventilation for gas appliances of rated input not exceeding 70kW net 1st 2nd and 3rd family gases Part 2 Specification for installation and maintenance of ventilation for gas applia...

Page 12: ... also be used as a type B23 appliance If such a configuration is to be used then appropriate ventilation for cooling and combustion must be provided For further details please refer to Section 9 AIR SUPPLY or to BS5440 2 or BS6644 as appropriate 6 2 GENERAL REQUIREMENTS Corrosion of the heat exchanger coils and flue system may occur if air for combustion contains certain chemical vapours Such corr...

Page 13: ...atural Gas 2H appear below for details relating to Propane 3P please refer to Section 14 LPG FUEL 7 1 SERVICE PIPES The local gas distributor must be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas An existing service pipe must not be used without prior consultation with the local gas distributor 7 2 METERS A new gas meter will be co...

Page 14: ...OSITIONS Location Description EKW45CE EKW60CE EKW85CE EKW235CE A Directly below an opening air brick opening windows etc 300 2000 B Above an opening air brick opening windows etc 300 1000 C Horizontally to an opening air brick opening windows etc 300 1000 D Below a gutter or sanitary pipework 75 75 E Below the eaves 200 200 F Below a balcony or car port roof 200 200 G From a vertical drain or soil...

Page 15: ...es the water heater connections concentric adaptor if required flue pipes air ducts if required and terminals If discharging at low level a suitable flue guard must be installed Due to the condensing nature of the water heater long external runs should be avoided to prevent the condensate freezing within the flue system During assembly precaution should be taken to ensure that the internal sealing...

Page 16: ...URE 8 2 FLUE CONNECTION DETAILS EKW45CE EKW60CE ITEM DESCRIPTION 1 Flue Gas Test Point 2 Concentric Adaptor 3 80mm Dia x 500mm Length 4 90 Elbow 5 Air Intake Transition 6 Intake Connection Reducer 7 Exhaust Transition TABLE 8 2 FLUE CONNECTION DETAILS EKW45CE EKW60CE ...

Page 17: ...ransition Item 5 in Figure 8 2 into the intake connection reducer Item 6 and tighten the worm drive clip 4 To the bottom exhaust connection of the concentric adaptor Item 2 in Figure 8 2 fit the 80mm dia x 500mm length then fit one 90 elbow to the 500mm length 5 To the side intake connection of the concentric adaptor fit the remaining 90 elbows 6 Fit the exhaust section of the assembly to the heat...

Page 18: ...CE EKW145CE ITEM DESCRIPTION 1 Flue Gas Test Point 2 Concentric Adaptor 3 100mm Dia x 500mm Length 4 90 Elbow 5 Exhaust Transition 6 Intake Connection 7 Air Intake Transition TABLE 8 3 FLUE CONNECTION DETAILS EKW85CE EKW145CE FIGURE 8 5 CUTTING ITEM 3 1 TO LENGTH X X ...

Page 19: ...een the centre of the air intake connection and the concentric adaptor See Figure 8 5 5 Remove the 100mm dia x 500mm length and cut the measured distance from the plain end See Figure 8 5 6 Insert the air intake transition Item 7 in Figure 8 4 into the intake connection Item 6 and tighten the worm drive clip 7 To the side intake connection of the concentric adaptor fit one of the 100mm dia x 500mm...

Page 20: ...6 into the intake connection Item 1 and tighten the worm drive clip 8 7 4 EKW205CE EKW235CE FIGURE 8 7 FLUE CONNECTION DETAILS EKW205CE EKW235CE ITEM DESCRIPTION 1 Intake Connection 2 Air Intake Transition 3 Exhaust Transition 4 Flue Collar TABLE 8 5 FLUE CONNECTION DETAILS EKW205CE EKW235CE To install the flue connection to the EKW205CE EKW235CE water heaters the following procedure should be fol...

Page 21: ... distances as detailed in Figure 8 1 Table 8 1 and the relevant British Standards 2 Taking care to protect the appliance from debris and dust drill a hole in the desired location The diameter of the hole should be no more than 10mm greater than the diameter of the air supply pipe of the terminal 3 Determine the required length of the terminal and cut as necessary NOTE When determining the required...

Page 22: ...ng material Extra care should be taken to ensure that the hole is drilled vertically 4 Install the roof flashing and secure as appropriate 5 Carefully insert the roof terminal through the roof flashing and hole in the roof NOTE When inserting the roof terminal do not support or turn the terminal using the cap 6 Ensure the terminal is vertical using a spirit level 7 Fit the support bracket around t...

Page 23: ...e installed on opposite sides of the building To install a Type C53 terminal or air inlet the procedure for either a Type C13 horizontal or a Type C33 vertical terminal should be followed noting that the annular space of the terminal should be sealed off 8 9 FLUE TERMINAL GUARDING If a horizontal flue terminal is to be fitted less than 2 metres from ground level or in a location where it can be to...

Page 24: ...5CE 117 2 105 6 212 424 318 530 424 636 530 1060 636 1166 742 1272 EKW145CE 146 5 132 0 264 528 396 660 528 792 660 1320 792 1452 924 1584 EKW175CE 175 8 158 4 318 636 477 795 636 954 795 1590 954 1749 1113 1908 EKW205CE 205 2 184 5 370 740 555 925 740 1110 925 1850 1110 2035 1295 2220 EKW235CE 234 5 211 3 424 848 636 1060 848 1272 1060 2120 1272 2332 1484 2544 TABLE 9 2 COMBUSTION VENTILATION REQ...

Page 25: ...seful heating surface should be insulated Cisterns expansion vessels and pipework situated in areas exposed to freezing conditions should also be insulated 3 Drain valves must be located in accessible positions that will permit draining of the entire system including the unit and the storage vessel 4 Tapping sizes for connection to the water system are detailed in Table 3 1 5 Ideally individual va...

Page 26: ...and a primary pipework loop The primary loop should be no longer than 14 metres plus the following fittings 6 x 90 Elbows 2 x Unions 2 x Full bore lever ball valves 2 x Tee fittings cold feed building return For longer distances or a greater number of fittings the pump may have to be resized The specification of this type of pump ensures that the bronze body and associated parts in contact with wa...

Page 27: ... front cover of the appliance Provision should be made to install this sensor in the flow pipework in the required location ensuring that any reducing fittings used allow the pocket to by sufficiently immersed in the water flow to correctly register the temperature FIGURE 10 1 DRY POCKET SENSOR INSTALLATION 10 6 2 STRAP ON SENSOR Where it is not possible to fit the dry pocket sensor the strap on p...

Page 28: ...1 1 EXTERNAL CONTROLS The Lochinvar EcoKnight is compatible with the following control and safety systems Building Management System BMS 0 10VDC analogue input Storage vessel thermostat on off type Storage vessel sensor modulating type Internal sequencing control Gas pressure switch e g gas booster under pressure over pressure safety switch Water flow proving device e g differential pressure switc...

Page 29: ...rn pump If the pump rating exceeds 190 watts the Live and Neutral connections should be used to energise a suitable contactor MAINS Connections for a 230V 1 ph 50Hz power supply NOTE the power supply cable should be secured using the anchor supplied or an equivalent TABLE 11 2 HIGH VOLTAGE CONNECTION TERMINAL DETAILS 11 3 LOW VOLTAGE CONNECTOR STRIP AUX DEVICE PILOT SUPPLY 24VAC GND AUX DEVICE PRO...

Page 30: ...the heater locking out This connection can be used by a BMS to monitor the operation of the heater 15 16 FLOW SWITCH If a flow switch is to be used to ensure the primary pump is operating the link should be taken out of pins 15 16 and the flow switch wiring installed If there is no continuity across the terminals the heater will not fire 17 18 GAS PRESSURE SWITCH If a gas pressure switch is to be ...

Page 31: ...a knockout is removed by mistake the resulting hole must be blocked with an appropriate anchor plug or grommet to prevent accidental access to the live parts within the heater 11 5 FUSES The EcoKnight has five internal fuses F1 will automatically reset F2 F5 are slow blow fuses located and rated as follows FIGURE 11 4 FUSE RATINGS AND LOCATIONS The water heater has three spare fuses in a plastic b...

Page 32: ...bles can lead to operational problems which could result in non repairable damage to the integrated controller or other components minimum of 105 C Exceptions Replacement high voltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having s...

Page 33: ...wn on diagrams depending upon whether utilities electricity connected to the unit As such actual switch states may 1 Where possible switches are shown without utilities gas water or NOTES CN4 14 X6 2 X2 2 19 20 21 22 17 10 18 16 15 HIGH VOLTAGE SPARK LEAD CAUTION HIGH VOLTAGE LOW VOLTAGE 230 VAC CONTROL INTEGRATED INTEGRATED CONTROL ROD SPARK FLAME ROD X1 7 TR1 1 25A F3 3 5A F2 3 5A F4 5A 5 4 2 1 ...

Page 34: ...ROL 12 1 GENERAL The Lochinvar EcoKnight uses the SMART SYSTEM control interface The control panel display give information on set up system status and diagnostic data in words rather than codes 12 2 SMART SYSTEM CONTROL PANEL ...

Page 35: ...s complete and the blocked drain and auto reset high limit are closed the control starts the 5 second trial for ignition by sending spark voltage to the ignition electrode and opening the gas valve WHR IGNITION OUT 61 5C 65 5 If the control does not detect flame by the end of the trial for ignition the control performs a 10 second postpurge On the EKW45CE to EKW115CE models the control will perfor...

Page 36: ...talled the control will display the inlet temperature as well as the set point in brackets OPEN The control does not detect the inlet sensor SHORTED The inlet sensor wires or the sensor itself has become shorted RISE C The difference between the inlet temperature and the outlet temperature Press the Next arrow key on the SMART SYSTEM display to access Screen 3 3 FLUE C The control will display the...

Page 37: ...g for a fixed time to remove any residual heat Press the Next arrow key on the SMART SYSTEM display to access Screen 8 8 Cas Pow The first percentage shows the firing rate that is being sent to the last water heater called on The second percentage shows the total power available to the Cascade Present 01234567 Example Present 23 01 Shows the number of water heaters connected to the Cascade The Mas...

Page 38: ...re that personnel involved are aware of what action is about to be taken and begin by making the following checks 1 Flueway passages are clear 2 Adequate ventilation exists in the plant room if necessary 3 The system is fully charged with water ready to receive heat All necessary valves are open and the building return pump if fitted is circulating water 4 The gas supply pipework is clear of any l...

Page 39: ...chinvar EcoKnight series are supplied with a preset gas air ratio inlet assembly This must not be tampered with Any attempt to adjust the gas valve or venturi will invalidate the warranty Combustion figures should be as follows Model No CO2 CO EKW45CE 9 0 0 5 100 ppm EKW60CE 9 0 0 5 100 ppm EKW85CE 8 8 0 5 100 ppm EKW115CE 8 8 0 5 100 ppm EKW145CE 8 8 0 5 100 ppm EKW175CE 9 0 1 0 100 ppm EKW205CE ...

Page 40: ...ed stainless steel or copper The operation of the EcoKnight range on LPG Propane 3rd Family 3P is similar to that on Natural Gas 2nd Family 2H and the design and installation details described in the main body of the installer s guide should be followed 14 2 CONVERSION TO LPG This process must be carried out in the order stated Failure to follow the following procedure may lead to non warrantable ...

Page 41: ... the stamping on the orifice disk is correct for the water heater see Table 14 1 Place the orifice into the black rubber grommet in the side of the gas valve ensuring the orifice and grommet are seated correctly Figure 14 1 5 Reposition the gas valve against the venturi and replace the cap head screws Figure 14 1 securing the valve to the venturi 6 Refit the impulse tube and wiring plug to the gas...

Page 42: ...of the gas valve and replace it with the orifice from the kit Position and secure the orifice in the valve as shown in Figure 14 2 7 Reposition the gas valve against the venturi and replace the star drive screws Figure 14 2 securing the valve to the venturi 8 Inspect the O ring inside the fan Handle the O ring with care do not damage Reposition the venturi against the fan and replace the screws se...

Page 43: ...e the 4 cap head screws securing the gas valve to the venturi supporting the valve at all times 6 Separate the valve from the venturi inspect the sealing gasket and retain or replace as necessary 7 Fit the new valve using the reverse of the above procedure ensuring the new or retained gaskets are correctly seated 8 After installation is complete attach the propane conversion label in the conversio...

Page 44: ...ng orifice from the O ring in the side of the injector plate and replace it with the orifice from the kit Position and secure the orifice in the injector plate as shown in Figure 14 4 7 Reposition the manifold adapter to the injector plate and replace the four manifold adapter mounting screws Handle the O ring with care do not damage 8 Reposition the injector plate to the air shroud and replace th...

Page 45: ...rrect for the heater see Table 14 1 5 Fit the orifice plate ensuring its correct orientation see DETAIL A of Figure 14 5 6 Reinstall the four screws and nuts holding the adapter flange to the inlet of the venturi ensuring the correct location of the gasket 7 After installation is complete attach the propane conversion label in the conversion kit bag next to the heater rating plate Attach the LPG w...

Page 46: ...sure that the flue its support and terminal the ventilation to the boiler house safety valve drain pressure gauge etc are in a serviceable and working condition and still comply with the relevant standards and codes of practice as detailed in Section 4 GENERAL REQUIREMENTS Servicing is recommended at intervals no greater than 12 months to ensure trouble free operation Even if the maintenance sched...

Page 47: ...heat exchanger front plate and burner assembly from the heat exchanger complete with the combustion fan 8 With the burner assembly away from the boiler the burner can be gently cleaned with the brush attachment of a vacuum cleaner The reassembly procedure is the reverse of the above taking care to ensure that the for the heat exchanger front plate sealing gasket the combustion fan connection gaske...

Page 48: ...age the lining of the vessel 5 Inspect cleanout plate gasket and replace if necessary 6 Install gasket and cleanout plate Draw the plate up square by tightening the bolts evenly 7 Once the system has been re filled and a check for leaks carried out the outer cover plate should be re fitted 15 8 SACRIFICIAL ANODES INSPECTION AND REPLACEMENT STORAGE VESSELS If the Correx non sacrificial anode protec...

Page 49: ...kit will require replacing after 12 months of operation Please refer to the item specific instructions for further details 16 0 SMART SYSTEM CONTROL SETTINGS 16 1 ENTERING THE INSTALLER CODE To access the user control the following procedure should be followed 1 If the heater is operating press the Enter Reset button to turn the unit off 2 Press and hold the Menu Exit button for 5 seconds At this ...

Page 50: ...ts the method used to control the modulation of the water heater By using the Up and Down buttons and then pressing the Enter Reset button one of the following control modes can be selected Thermostat The control modulates the water heater based on the user set point and the temperature of the tank sensor when a tank thermostat is used or the inlet sensor BMS Building Management System The control...

Page 51: ...play will alternate the standard water heater display text with the message SERVICE DUE every 5 seconds This parameter is adjustable in 500 hour intervals using the Up or Down buttons and then stored by pressing the Enter Reset button The time range for this parameter is 0 hours to 100 000 hours The default time is 10 000 hours 16 6 3 SERVICE NOTIFICATION BOILER CYCLES When the water heater contro...

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